New Turning Technologies for the Automotive Industry

ISCAR's innovative metal cutting tools have a direct impact on the automotive industry's processing time savings.

ISCAR's innovative technical approach, especially with FMR (Fast Metal Removal) tools, has resulted in many successful cases. Many customers are fully enjoying these advances, especially in turning, grooving, cutting and hole machining tools. When we analyze the improvement of processing methods, whether we can reduce production time is the most significant data, in the processing cycle time. One of the factors that can affect the cost of a single piece of production is the use of new processes in processing.

Other elements are:

The use of "intelligent" and stable machine tools;

The use of innovative tools allows the most processed products in the shortest possible time - that's what we're talking about productivity.

Today, many companies in the automotive industry are making a shift to replace traditional inefficient tools with efficient ones.

ISCAR's HELITURN TG and HELITURN LD car knives have high-tech grooves and blade substations and coatings for beam magic technology. Many automotive forgings, such as gear shafts, spindles and sub-spindles, are undergoing changes in turning and fine vehicle processes. ISCAR's innovative turning methods reduce machining time by 30% to 50%, even in processes that require a large amount of metal removal. With ISCAR turning tools, you can generate significant savings and reduce turning time by reducing the number of passes and increasing the yield.

Grooving - turning.

ISCAR was the first company to explore and implement integrated grooving and turning tools, resulting in heLI-GRIP and CUT-GRIP overlord knives. These solutions have greater advantages than traditional methods and have been used as an industrial standard for turning certain automotive components.

These tools are designed specifically for the production of spindles, camshafts, hydraulics and gears, meeting the challenges of strict tolerances and complex machining. It reduces the number of tools by 60% compared to conventional knives. More importantly, it really reduces the time it takes to adjust the knife. Using such a multi-function tool, grooving and turning operations between square shoulders can be completed in turn.

These unique tools can effectively reduce the number of tools in a given turning cycle, thereby reducing production time by 30%. For the camshafts used to make trucks, ISCAR has designed the ideal tool with a blade width of 28mm, which can be machined at once. This blade has a unique chip-breaking groove, which is very short, allowing the chip to be quickly discharged from the processing area to form an ultra-light work surface. Due to the smooth discharge of short chips, this blade ensures continuous barrier-free processing. At the same time, highly rigid V-shaped clamping is used for stable metal removal, ensuring a high level of surface quality.

Process high-hard steel parts.

In the past few years, more and more parts in the automotive industry have been made of hardened steel.

WHEN processing quenched steel (HRC52-65), ISCAR's full range of CBN (cubic boron nitride) ISO blades and CUT-GRIP blades perform well.

ISO's standard blade slots, such as CNGA, WNGA, DNGA and TNGA, offer 4- or 6-blade multi-angle blades in addition to single-edged CBN blades.

ISCAR also offers ceramic blades for quenching steel processing. These blades are more economical than CBN blades, allowing for high hardness parts to be cut at high metal removal rates.

Cast iron.

The brake disc is the most common cast iron part in automotive parts. ISCAR offers the perfect ceramic blade solution for processing this part at a very high removal rate. ISCAR's blade materials are IS8, IS80, IN11, IN22, IN23 and the latest IS6 (SiAlON), which are ideal for cutting speeds up to 600m/min.

Aluminium wheels.

Another common automotive component is aluminum wheels, and ISCAR has a good tool and blade groove in this area and has accumulated many success stories.

ISCAR offers a wide range of tools and blades in this type of machining. The new range of tools, called CLICKFIT, features a unique modular interface that provides high rigidity for changeable heads and is used to mount different ISO and CUT-GRIP blades. This system exhibits ultra-rigidity, ensuring superior surface quality by processing aluminum wheels in extreme operating conditions.

ISCAR has a full range of polished PCD blades, some with chip slots, ensuring consistency in roughing and finishing quality.

Piston.

ISCAR is also very experienced in the production of piston machining tools and has achieved many outstanding results. Through joint efforts with piston manufacturers, ISCAR has developed a piston manufacturing process using the Overlord Knife. These highly composite tools can use a variety of complex shaped blades in the machining cycle and are highly stable.

The high production and processing costs of some automotive parts create production bottlenecks, and "more flexible" tools need to be developed here.

In the past, many companies were reluctant to try out new tools, mistakenly thinking it was a waste of time. Now, however, they are realizing that using these high-tech products can keep them competitive.

ISCAR tool development focuses on tool and blade grooves and is dedicated to reducing cutting forces and machine power consumption. The combination of these concepts has significantly improved processing conditions and effectively reduced manufacturing costs.